CN104995425A - A method of making a brake disc, brake disc for disc brake and a disc brake - Google Patents
A method of making a brake disc, brake disc for disc brake and a disc brake Download PDFInfo
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- CN104995425A CN104995425A CN201380072767.9A CN201380072767A CN104995425A CN 104995425 A CN104995425 A CN 104995425A CN 201380072767 A CN201380072767 A CN 201380072767A CN 104995425 A CN104995425 A CN 104995425A
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- Prior art keywords
- brake disc
- protective coating
- weight percentage
- particulate forms
- coating
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Links
- 238000004519 manufacturing process Methods 0.000 title claims description 20
- 239000011253 protective coating Substances 0.000 claims abstract description 89
- 239000000463 material Substances 0.000 claims abstract description 82
- 238000000034 method Methods 0.000 claims abstract description 56
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 47
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 47
- 238000000151 deposition Methods 0.000 claims abstract description 45
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 28
- 238000007773 kinetic metallization Methods 0.000 claims abstract description 21
- 239000002245 particle Substances 0.000 claims abstract description 19
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000010941 cobalt Substances 0.000 claims abstract description 16
- 229910017052 cobalt Inorganic materials 0.000 claims abstract description 16
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims abstract description 16
- 239000000446 fuel Substances 0.000 claims abstract description 11
- 239000011651 chromium Substances 0.000 claims abstract description 8
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 7
- 238000000576 coating method Methods 0.000 claims description 77
- 239000011248 coating agent Substances 0.000 claims description 75
- 230000008021 deposition Effects 0.000 claims description 34
- 238000005137 deposition process Methods 0.000 claims description 33
- 238000005516 engineering process Methods 0.000 claims description 29
- 239000000835 fiber Substances 0.000 claims description 28
- 238000007749 high velocity oxygen fuel spraying Methods 0.000 claims description 17
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 17
- 229910052721 tungsten Inorganic materials 0.000 claims description 17
- 239000010937 tungsten Substances 0.000 claims description 17
- 239000000203 mixture Substances 0.000 claims description 13
- 229910000831 Steel Inorganic materials 0.000 claims description 11
- 239000003082 abrasive agent Substances 0.000 claims description 11
- 239000008041 oiling agent Substances 0.000 claims description 11
- 239000010959 steel Substances 0.000 claims description 11
- 238000005507 spraying Methods 0.000 claims description 10
- 230000003746 surface roughness Effects 0.000 claims description 9
- 239000012764 mineral filler Substances 0.000 claims description 8
- 230000009471 action Effects 0.000 claims description 6
- 230000004069 differentiation Effects 0.000 claims description 4
- 238000011017 operating method Methods 0.000 claims description 3
- 238000007750 plasma spraying Methods 0.000 claims 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 abstract description 5
- 229910052760 oxygen Inorganic materials 0.000 abstract description 5
- 239000001301 oxygen Substances 0.000 abstract description 5
- 238000010286 high velocity air fuel Methods 0.000 abstract 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 abstract 1
- 238000012360 testing method Methods 0.000 description 31
- 239000002783 friction material Substances 0.000 description 21
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 20
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 18
- 230000008569 process Effects 0.000 description 17
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 16
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 15
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 12
- 229910052799 carbon Inorganic materials 0.000 description 10
- 229910052742 iron Inorganic materials 0.000 description 10
- 239000004411 aluminium Substances 0.000 description 9
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 7
- 239000010428 baryte Substances 0.000 description 7
- 229910052601 baryte Inorganic materials 0.000 description 7
- 239000000571 coke Substances 0.000 description 7
- 239000010439 graphite Substances 0.000 description 7
- 229910002804 graphite Inorganic materials 0.000 description 7
- 238000000465 moulding Methods 0.000 description 7
- 229910052759 nickel Inorganic materials 0.000 description 7
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 6
- 229910052802 copper Inorganic materials 0.000 description 6
- 239000010949 copper Substances 0.000 description 6
- 239000000395 magnesium oxide Substances 0.000 description 6
- 235000012245 magnesium oxide Nutrition 0.000 description 6
- 239000010455 vermiculite Substances 0.000 description 6
- 229910052902 vermiculite Inorganic materials 0.000 description 6
- 235000019354 vermiculite Nutrition 0.000 description 6
- 229910001060 Gray iron Inorganic materials 0.000 description 5
- 239000004760 aramid Substances 0.000 description 5
- 229920003235 aromatic polyamide Polymers 0.000 description 5
- 230000008878 coupling Effects 0.000 description 5
- 238000010168 coupling process Methods 0.000 description 5
- 238000005859 coupling reaction Methods 0.000 description 5
- 229920001971 elastomer Polymers 0.000 description 5
- 229910001018 Cast iron Inorganic materials 0.000 description 4
- 210000001138 tear Anatomy 0.000 description 4
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000000875 corresponding effect Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229920001568 phenolic resin Polymers 0.000 description 3
- 239000005011 phenolic resin Substances 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 238000004381 surface treatment Methods 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 239000011135 tin Substances 0.000 description 2
- 229910052718 tin Inorganic materials 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 229910052725 zinc Inorganic materials 0.000 description 2
- 239000011701 zinc Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 238000004873 anchoring Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000012512 characterization method Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical compound [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
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- 239000000428 dust Substances 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 230000012447 hatching Effects 0.000 description 1
- 230000003116 impacting effect Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000001465 metallisation Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 238000005381 potential energy Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
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- 239000002904 solvent Substances 0.000 description 1
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- 239000010421 standard material Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 229910003470 tongbaite Inorganic materials 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
- F16D65/127—Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
- F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
- F16D69/02—Composition of linings ; Methods of manufacturing
- F16D69/027—Compositions based on metals or inorganic oxides
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
- F16D2069/003—Selection of coacting friction materials
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D2250/00—Manufacturing; Assembly
- F16D2250/0038—Surface treatment
- F16D2250/0046—Coating
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Inorganic Chemistry (AREA)
- Braking Arrangements (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
The present invention relates to a method for making a brake disc comprising the following operating steps: a) providing a brake disc, comprising a braking band 2 made of aluminum or aluminum alloy and provided with two opposite braking surfaces 2a, 2b, each of which at least partially defines one of the two main sides of the disc; b) depositing a material in particle form on the disc with HVOF (High Velocity Oxygen Fuel) technique or with HVAF (High Velocity Air Fuel) technique or with KM (Kinetic Metallization) technique, forming a protective coating 3 which covers' at least one of the two braking surfaces of the braking band. The material in particle form is composed of 80 to 90% by weight of tungsten carbide, 8% to 12% by weight of cobalt and 2% to 6% by weight of chromium.
Description
Technical field
The present invention relates to a kind of manufacture brake disc method, for the brake disc of disk type braker and disk type braker.
Background technique
The brake disc of the disk braking system of vehicle comprises loop configuration, or clamping strap, and central authorities' attachment element (being called as bell), by these central authorities attachment element, brake disc is attached to the rotating part of vehicle suspension, such as wheel hub.Clamping strap is provided with the contrary braking surface being suitable for coordinating with friction element (brake pad), and these friction elements are contained at least one caliper, and described caliper forms entirety across described clamping strap and with the on-rotatably moving part of vehicle suspension.Controlled interaction between relative brake pad and the contrary braking surface of clamping strap determines the braking action caused by rubbing, and this makes vehicle deceleration or stopping
Usually, brake disc is made up of grey cast iron.In fact, this material allows to obtain good braking ability (particularly in suppression wearing and tearing) with relatively low cost.The brake disc be made up of carbon or carbon ceramic material can provide better performance, but cost is much higher.
A limitation not yet overcome of cast iron brake disk is relevant to the excessive weight of brake disc.
Attempt overcoming this problem by manufacturing the aluminum Moving plate with protective coating.This protective coating is used for reducing brake disc wear thus therefore guaranteeing the performance similar with cast iron brake disk on the one hand, is used on the other hand protecting aluminium base from the temperature of the softening temperature higher than aluminium (200-400 DEG C) produced during braking.
But, at present obtainable, can be applicable to aluminum Moving plate and the protective coating of wear resistance is provided simultaneously, the problem come off causing it from aluminum Moving plate separation itself can be run into.
Such as, describe such protective coating in patent US 4715486, this patent relates to a kind of low wearing and tearing disk type braker.Particularly, the dish be made of cast iron has the coating made by the material of particulate forms, uses kinetic energy impact technology to deposit this coating on dish.According to the first embodiment, coating comprises the Tungsten carbite of 20% to 30% and the nickel of 5%, and remainder is made up of the mixture of chromium carbide and tungsten.According to the second embodiment, coating comprise 80% to 90% Tungsten carbite, the cobalt up to 10%, the chromium up to 5% and up to 5% carbon.
Have been found that the main cause that traditional protective coating is separated from aluminum or aluminum alloy brake disc there is nickel in protective coating.
If use coating by flame spray technique, second reason that so traditional protective coating is separated from aluminum or aluminum alloy brake disc there is free carbon in protective coating.In fact, carbon is easy to burning, thus combines with the oxygen be contained in formed protective coating.This causes forming micro gas-bubble in coating, and this may stop coating to bond fully on the disc brake rotor, makes coating be easy to be separated.
It is evident that from the above, the brake disc of the coating of being made up of aluminum or aluminum alloy cannot use at present in braking system field.
But consider the advantage using aluminium to bring to the weight reducing brake disc, the demand that sensation solves the problem mentioned with reference to prior art is in the art very large.Particularly, the demand that wear resistance aluminum Moving plate being had can increase brake disc increases the protective coating of resistance has simultaneously been experienced.
A subject matter of disk type braker is, extends the working life of braking surface and brake pad.
As everyone knows; in fact; the reason of the friction material identical with brake pad (its in braking action process between braking surface and brake pad) such as owing to breaking into pieces in dirt or braking process, can produce vestige or other surface imperfection fast in braking surface.These surface imperfections can produce makes us uncomfortable noise or quack sound and the wearing and tearing increasing brake disc and brake pad thereof to a large extent.In practice, these shortcomings can limit the working life of brake disc due to the service travelling comfort of deficiency and excessive component wear.
Compare with the brake disc be made up of carbon ceramic material, in the brake disc made with traditional material, above wear problem is outstanding especially, such as grey cast iron and aluminum or aluminum alloy.
Therefore, if experience the demand of the wearing and tearing of the brake disc that reduction is particularly made up of aluminium or grey cast iron and the wearing and tearing of brake pad especially, to alleviate above shortcoming.
On brake disc side, the brake disc by providing coating to be designed for the protective material promoting wear resistance, solves this problem.Particularly, the protective coating of a type comprises the mixture using ceramic powder and binding metal material.
On brake pad side, by providing the friction material of also test different types to solve this problem in many ways.
The very general friction material of one type comprises the material obtained by hot moulding, and this material is made up of fiber, abrasives, oiling agent, metallic material and polymerisable tackiness agent (such as phenolic resin).
An example of friction material is described in US20060151268.This friction material comprises iron fiber, aluminum fiber, zinc fiber and tin fiber.Iron fiber volume flow rate percentage is between about 1% and about 10%.The volume flow rate percentage of aluminium, zinc and tin fiber is between about 1% and about 5%.Friction material does not have elemental copper, is in use released in environment to prevent copper.Particularly, this friction material comprises graphite and/or the coke of the volume of about 11%, or only comprises the graphite of volume of about 6%.This material also comprises the aluminium oxide of the volume of about 3%, or the zirconium oxide of the volume of about 5%.
As everyone knows, have good frictional behaviour and parts have the braking system of high wear resistance to obtain, must calibrate the feature of brake disc by the feature of brake pad, vice versa.Usually, in fact, the parts (brake disc and brake pad) obtained separately show extraordinary performance (such as in wear resistance), then when used in combination, if not too poor, can obtain medium result.
Therefore, experience the demand determining a kind of disk type braker especially, this disk type braker provides good friction performance and improves the performance of each parts being worn and tearing (that is, brake disc and brake pad).
Summary of the invention
By the method for manufacture brake disc according to claim 1 and by the brake disc for disk type braker according to claim 12; meet the demand to the aluminum Moving plate being provided with protective coating, the wear resistance that this protective coating can increase brake disc can increase ageing resistance simultaneously.
Particularly, a kind of method by manufacture with the brake disc made of aluminum of protective coating meets this demand, and the method comprises following operating procedure:
A) provide brake disc, described brake disc comprises clamping strap, and this clamping strap is made up of aluminum or aluminum alloy and is provided with two contrary braking surfaces, and each braking surface limits one in two masters of brake disc at least in part;
B) HVOF (high velocity oxygen fuel spraying) technology or HVAF (velocity air fuel spraying) technology or KM (kinetic metallization) technology is used by the deposition of material of particulate forms on the disc brake rotor, to form the protective coating of at least one in two braking surfaces covering clamping strap.
The material of this particulate forms comprise weight percentage be 80% to 90% Tungsten carbite, weight percentage be 8% to 12% cobalt and weight percentage be the chromium of 2% to 6%.
According to a preferred embodiment of the method, the material of this particulate forms comprise weight percentage be 86% Tungsten carbite, weight percentage be 10% cobalt and weight percentage be the chromium of 4%.
Preferably, the granularity of the particle of the material of this particulate forms is between 5 and 40 μm.
According to one of the method possible embodiment, protective coating has the thickness between 20 μm and 100 μm, particularly between 20 μm and 80 μm.
According to a preferred embodiment of the method, deposition step b) be included in the two or more independent deposition process of the material of this particulate forms in similar face, to form protective coating.
Particularly, deposition step b) comprise and directly deposit the material of this particulate forms on the disc brake rotor to produce the first deposition step of the base layer of coating, and the material depositing this particulate forms on this base layer is to produce second deposition step of finishing coat (finishing layer).The granularity of the material of the particulate forms by the second deposition process deposition is greater than by the granularity of the material of the particulate forms of the first deposition process deposition.
According to a specific embodiments of the method, the granularity of the material of the particulate forms deposited by the first deposition process is between 30 and 40 μm.The granularity of the material of the particulate forms deposited by the second deposition step is between 5 and 20 μm.
Particularly, protective coating has the surface roughness Ra of 2.0 to 3.0 μm at finishing coat place.
Particularly, the thickness of the base layer of this coating is between 2/4 and 3/4 of the total thickness of this coating.The thickness of finishing coat is between 1/4 and 2/4 of the total thickness of this coating.
According to one of the method possible embodiment, whole brake disc is made up of aluminum or aluminum alloy.
According to one of the method possible embodiment, protective coating covers the whole surface of brake disc.
According to a specific embodiment of the method, at deposition step b) in, the material of described particulate forms at least based on described protective coating thickness and be deposited in the mode of differentiation on the surface of described brake disc.
Particularly, each master of described dish is at least limited by the first annular portion corresponding with the braking surface of clamping strap, and is limited by the second annular portion, and described second annular portion than the first annular portion more inwardly and the attachment area of restriction dish and vehicle.At described deposition step b) in, manufacture the protective coating at least covering these two parts.The thickness that the coating that the Thickness Ratio that the coating that described first annular portion manufactures has manufactures on described second portion has is larger.
Particularly, above-mentioned needs are met by a kind of brake disc 1 for disk type braker, described brake disc comprises clamping strap 2, described clamping strap is made up of aluminum or aluminum alloy and is had two contrary braking surface 2a and 2b, and each braking surface limits one in two masters of described dish at least partly.Described dish 1 has protective coating 3, and described protective coating covers at least one in two braking surfaces of clamping strap.Tungsten carbite, weight percentage that this coating is 80% to 90% by weight percentage be 8% to 12% cobalt and weight percentage be 2% to 6% chromium form.By using HVOF technology or HVAF technology (velocity air fuel spraying) or KM technology (kinetic metallization), the component of the particulate forms of deposited coatings on coiling, thus obtain described coating.
According to a preferred embodiment of this brake disc, Tungsten carbite, weight percentage that coating 3 is 86% by weight percentage be 10% cobalt and weight percentage be 4% chromium form.
Preferably, by the described composition of the particulate forms of deposit grain size between 5 and 40 μm on the disc brake rotor, this coating is obtained.
According to a specific embodiments of this brake disc, protective coating has the thickness between 20 and 100 μm, more specifically between 20 and 80 mum.
According to a specific embodiments of this brake disc; protective coating is made up of base layer and top finishing coat; described base layer is directly related and made by the first deposition step of the material of particulate forms with dish, and described top finishing coat to be arranged on described base layer and to be made by the second deposition step of the material of particulate forms.The granularity that the material that the fineness ratio that the material of the particulate forms deposited in the first deposition process has deposits in the second deposition process has is larger.。
Particularly, the material of the particulate forms deposited in the first deposition process has the granularity of 30 to 40 μm, and the material of the particulate forms deposited in the second deposition process has the granularity of 5 to 20 μm.
Particularly, protective coating has the surface roughness Ra of 2.0 to 3.0 μm at finishing coat place.
According to one of this brake disc possible embodiment, the thickness of base layer is between 2/4 and 3/4 of the total thickness of this coating, and the thickness of finishing coat is between 1/4 and 2/4 of the total thickness of this coating.
According to one of this brake disc possible embodiment, whole brake disc is made up of aluminum or aluminum alloy.
According to one of this brake disc possible embodiment, protective coating covers the whole surface of brake disc.
According to a preferred embodiment of this brake disc, coating has different-thickness in the zones of different of panel surface.
Particularly, each master of described dish is at least limited by the first annular portion corresponding with the braking surface of clamping strap, and is limited by the second annular portion, and described second annular portion than the first annular portion more inwardly and the attachment area of restriction dish and vehicle.The coating that the Thickness Ratio that protective coating on described first annular portion has manufactures on described second portion is larger.
Met by brake disc according to claim 19 and determine to provide good friction performance and promote the demand of the disk type braker of the performance of each parts be worn (that is, brake disc and brake pad).
Particularly, by meeting this demand with lower disc brakes, described disk type braker comprises:
-brake disc, comprises clamping strap, and this clamping strap is provided with two contrary braking surfaces, and each braking surface limits one in two masters of brake disc at least in part;
-friction element, this friction element is suitable for being applied in order and coordinating with described braking surface, to determine braking action by friction.
Dish is provided with protective coating, and this protective coating covers at least one in two braking surfaces of clamping strap.Tungsten carbite, weight percentage that this coating is 80% to 90% by weight percentage be 8% to 12% cobalt and weight percentage be 2% to 6% chromium form.By using HVOF (high velocity oxygen fuel spraying) technology or HVAF technology (velocity air fuel spraying) or KM technology (kinetic metallization), the component of the particulate forms of deposited coatings on dish, thus obtain described coating.
The steel fiber that the oiling agent that abrasives, weight percentage that it is 10% to 40% that each friction element comprises by weight percentage are 8% to 40%, weight percentage are 5 to 30%, weight percentage be 6% to 18% organic bond and weight percentage be 10% to 20% the friction portion that forms of mineral filler, trim component (balance, balance portion) is made up of organic fill.
Preferably, the steel fiber that the oiling agent that abrasives, weight percentage that this friction portion is 25% to 30% by weight percentage are 25% to 30%, weight percentage are 15% to 20%, weight percentage be 8% to 15% organic bond and weight percentage be 10% to 20% mineral filler form, trim component is made up of organic fill.
This friction portion has 2g/cm
3with 3g/cm
3between density.Preferably, this density is at 2.60g/cm
3with 2.20g/cm
3between.
This friction portion have not higher than 10% porosity.
According to a preferred embodiment of this disk type braker, Tungsten carbite, weight percentage that coating 3 is 86% by weight percentage be 10% cobalt and weight percentage be 4% chromium form.
Preferably, by depositing the component of the particulate forms of the granularity had between 5 and 40 μm on the disc, this coating is obtained.
According to a specific embodiment of this disk type braker, protective coating has the thickness between 20 μm to 100 μm.
According to a specific embodiment of disk type braker; described protective coating is made up of base layer and top finishing coat; described base layer is directly related and made by the first deposition step of the material of particulate forms with dish, and described top finishing coat to be arranged on described base layer and to be made by the second deposition step of the material of particulate forms.The material that the fineness ratio that the material of the particulate forms deposited in the first deposition process has deposits in the second deposition process is larger.First deposition process with more coarsegrain allows the adhesive force improving protective coating, and second deposition process with smaller particle size allows reduction holes porosity.
Particularly, the material of the particulate forms deposited in the first deposition process has the granularity of 30 to 40 μm, and the material of the particulate forms deposited in the second deposition process has the granularity of 5 to 20 μm.
Particularly, protective coating has the surface roughness Ra of 2.0 μm to 3.0 μm at finishing coat place.
According to one of this disk type braker possible embodiment, the thickness of base layer is between 2/4 and 3/4 of the total thickness of this coating, and the thickness of finishing coat is between 1/4 and 2/4 of the total thickness of this coating.
According to one of this disk type braker possible embodiment, whole dish is made up of aluminum or aluminum alloy.
According to one of this disk type braker possible embodiment, the whole surface of protective coating covering disk.
According to a preferred embodiment of this disk type braker, coating has different-thickness in the zones of different of panel surface.
Particularly, each master of described dish is at least limited by the first annular portion corresponding with the braking surface of clamping strap, and is limited by the second annular portion, and described second annular portion than the first annular portion more inwardly and the attachment area of restriction dish and vehicle.The coating that the Thickness Ratio that the protective coating that described first annular portion manufactures has manufactures on described second portion is larger.
Advantageously, the friction portion of each friction element has the rupture modulus (rupture modulus) being greater than 20MPa, measures this rupture modulus with three-point bend test.
Advantageously, the friction portion of each friction element has the Young's modulus being greater than 8GPa, measures this Young's modulus with three-point bend test.
According to a preferred embodiment of the present invention, the abrasives be included in friction portion has granularity to be no more than the form of the particle of 60 μm.
Particularly, this abrasives comprises the particle of aluminium oxide and/or periclase (periclase).
According to a preferred embodiment of the present invention, this oiling agent is the form with the particle of granularity between 350 μm and 750 μm.
Particularly, this oiling agent comprises graphite and/or coke (coke).
According to a preferred embodiment of the present invention, this steel fiber comprises copper fiber and/or iron fiber.
Preferably, this organic bond is phenolic resin.
Particularly, this mineral filler comprises barite (barite) and/or vermiculite (vermiculite).
Particularly, this organic fill comprises rubber and/or aramid fibre.
Preferably, by being not less than 250kg/cm
2(be preferably not less than 550kg/cm
2) pressure lower mould, obtain the friction portion of each friction element.
Preferably, the friction portion of each friction element stands the heat of polymerization process of the organic bond of a period of time not being shorter than 5 minutes.
Accompanying drawing explanation
From the preferred description as nonrestrictive embodiment of the present invention given below, can clearly understand further aspect of the present invention and advantage, in the accompanying drawings:
Fig. 1 shows the top plan view of disk type braker according to an embodiment of the invention;
Fig. 2 shows the sectional view of the brake disc in the Fig. 1 of the hatching II-II indicated in Fig. 1;
Fig. 3, Fig. 4 and Fig. 5 respectively illustrate according to the present invention with according to two different alternative solutions, the photo of the clamping strap at the end of the testing results of the brake disc of disk type braker;
Fig. 6 and Fig. 7 respectively illustrates according to the present invention with according to an alternative solution, the photo of the clamping strap at the end of main AK test (master AK test) that the power stand of the brake disc of disk type braker carries out.
Element public between embodiment described below or the identical reference number of the parts of element represent.
Embodiment
With reference to above accompanying drawing, reference number 1 represents generally according to brake disc of the present invention.
Of the present invention general embodiment with reference to the accompanying drawings, brake disc 1 comprises to be made up of aluminum or aluminum alloy and to be provided with the clamping strap 2 of two opposed braking surfaces 2a and 2b, and each braking surface limits one in two masters of brake disc at least in part.
Brake disc 1 is provided with protective coating, and this protective coating covers at least one in two braking surfaces of clamping strap.
Tungsten carbite, weight percentage that this coating is 80% to 90% by weight percentage be 8% to 12% cobalt and weight percentage be 2% to 6% chromium form.
By the component of the coating by this particulate forms HVOF technology, or HVAF (velocity air fuel spraying) technology or KM (kinetic metallization) deposition techniques are on dish, obtain this coating.
In order to simplified characterization, now, brake disc 1 according to the present invention describes with method simultaneously.The method according to the present invention described now can preferably but non-essentially be used to manufacture brake disc 1.
According to the general embodiment according to method of the present invention, the method comprises following operating procedure:
A) provide brake disc, described brake disc comprises clamping strap 2, and described clamping strap is made up of aluminum or aluminum alloy and is provided with two contrary braking surface 2a and 2b, and each braking surface limits one in two masters of brake disc at least in part;
B) by the deposition of material of particulate forms dish on, with formed cover clamping strap two braking surfaces in the protective coating 3 of at least one.
Advantageously, brake disc manufacture has the part being suitable for brake disc being attached to vehicle, and this part is by being arranged in the central authorities of brake disc 1 and the annular portion 4 concentric with clamping strap 2 forms.Attachment part 4 support and connection are to the connecting element 5 of wheel hub (that is, bell).Bell can make one (as shown in drawings) with annular attachment part, or, or manufacture individually and be then attached to attachment part by suitable connecting element.
Annular attachment part 4 can be made up of aluminum or aluminum alloy or be made up of another suitable material, and as clamping strap.And bell 5 can be made up of aluminium (or aluminum alloy) or another suitable material.Particularly, whole dish (i.e. clamping strap, attachment part and bell) can be made up of aluminum or aluminum alloy.
Preferably, clamping strap 2 is manufactured by casting aluminum or aluminum alloy.Similarly, when being made up of aluminum or aluminum alloy, manufacture attachment part and/or bell by casting.
Annular attachment part can make one (as shown in drawings) with clamping strap, or this annular attachment part can manufacture independent body, is mechanically connected with clamping strap.
Preferably, at deposition step b) before be surface preliminary step c), the surface manufacturing protective coating thereon will be prepared in this preparation process.Particularly, preliminary step c) comprise the solvent clean surface using and be suitable for removing oil or dirt.Preferably, preliminary step c) polishing action on the surface of the disc can be comprised, such as, sand milling or polish.
According to a necessary aspect of the present invention, with HVOF technology or HVAF (velocity air fuel spraying) technology or KM (kinetic metallization) technology by the deposition of material of this particulate forms on dish.
These are well-known deposition technique for a person skilled in the art, therefore will be not described in detail.
HVOF is the spray deposition technique of powder, and this technology uses the spraying device with mixing and burning chamber and nozzle.Oxygen and fuel are fed to chamber.The hot combustion gas formed under close to the pressure of 1MPA is through scaling type nozzle, and dusty material reaches hypersonic speed (that is, more than 5 Mach).The dusty material that will deposit is injected in hot air flow, this material rapid melting in hot air flow and accelerating as about 1000m/s.Once encounter deposition surface, the material just cooling fast of fusing, and due to kinetic energy impact, so form the structure of very compact.
HVAF deposition technique (velocity air fuel spraying) is similar to HVOF technology.Difference is, in HVAF technology, by air but not oxygen feed to firing chamber.Therefore, involved temperature is lower than the temperature of HVOF.This allows the hydrothermal alternation better controlling coating.
KM deposition technique (power metallization) is solid deposited process, and wherein, metallic dust is sprayed by two-phase sound wave deposition nozzle, and this accelerates metallic and metallic triboelectric charge be supplied in inert gas flow inside.It is contemplated that heat energy to be supplied to conveying stream.In this process, the potential energy of the inert gas flow of compression and the kinetic energy of thermal energy powdered supplied.Accelerate at a high speed and electrically charged time, guide particle facing to deposition surface.The high velocity impact of metallic causes particle to be fully out of shape (normal orientation of impacting, about 80%).This distortion causes the surface area of particle significantly to increase.Therefore, impact and cause particle and deposition surface close contact, this causes being formed very fine and close and compact combinations of metals and coating.
Advantageously, substitute and listed abovely have three kinds of deposition techniques that identical kinetic energy impacts deposition technique, can also use other technologies, these technology use different deposition process, but can generate and have the very fine and close and coating of compact structure.
According to another basic sides of the present invention, Tungsten carbite (WC), weight percentage that the material of this particulate forms is 80% to 90% by weight percentage be 8% to 12% cobalt (Co) and weight percentage be 2% to 6% chromium (Cr) form.
Deposition technique HVOF, HVAF or KM and allow to obtain for the formation of the combination of the chemical composition of coating and have the protective coating of high bond strength, this guarantees to be anchored on aluminum or aluminum alloy to heavens.(compared with prior art solution) does not exist nickel significantly can reduce the danger that coating is separated with aluminium base or aluminum alloy.
Advantageously, the material of this particulate forms does not comprise nickel (Ni), and preferably even trace does not all have.In fact have been found that the main cause that conventional protective coatings is separated with aluminum or aluminum alloy brake disc there is nickel in protective coating.
Advantageously, the material of particulate forms does not comprise free carbon (C), and preferably even trace does not all have.In fact have been found that second reason that so conventional protective coatings is separated with aluminum or aluminum alloy dish has free carbon in protective coating when using flame spray technique to apply coating.In fact, carbon is easy to burning, thus combines with the oxygen in the protective coating being included in formation.This causes and forms microvesicle at coat inside, and this can stop coating sufficiently to adhere to described dish, is easy to coating is separated from dish.
In addition, this coating has high wear resistance.Show by brake disc according to the present invention is compared with the traditional braking dish be made up of grey cast iron the experimental test performed, under the same testing conditions, brake disc according to the present invention has the working life more much longer than traditional braking dish.For same size, the weight of aluminum Moving plate is approximately the half of the brake disc of grey cast iron.
Preferably, the material of this particulate forms is 86% by weight percentage Tungsten carbite, weight percentage be 10% cobalt and weight percentage be 4% chromium form.
This particular components allow wear resistance and with the cohesiveencess of aluminium in there is best result.
Preferably, the granularity of the particle of the material of this particulate forms is between 5 and 40 μm.The value of this scope is selected to allow to make coating have the feature of high density, high hardness and restricted porosity.
Protective coating 3 covers at least one in two braking surfaces of clamping strap.Preferably, as shown in Figure 2, the protective coating 3 that 1 is provided with two braking surface 2a and 2b covering clamping strap 2 is coiled.
Particularly, coating 3 only can cover clamping strap on a braking surface, or covers clamping strap on two braking surfaces.
Unshowned embodiment with reference to the accompanying drawings, protective coating 3 also may extend to the miscellaneous part of brake disc 1, as annular attachment part 4 and bell 5, to cover the whole surface of brake disc 1.Particularly, except clamping strap, coating only can also cover attachment part or only cover bell.This selection is only determined, to have uniform color and/or finishing coat over the complete disc or in its part from aesthetic consideration.
Preferably, protective coating has the thickness between 20 μm and 80 μm.The value of this scope is selected to allow to trade off well between the wearing and tearing and its thermal expansion of protective coating.In other words, if the thickness of protective coating is less than 20 μm, so will there will be when wearing and tearing and protective coating will be removed completely.On the other hand, due to the thermal expansion occurred in process in the working life of brake disc, the thickness being greater than 80 μm can cause faulty bonding.
Advantageously, at least can be applied in the mode of differentiation the deposition of material of particulate forms forming coating according to the thickness of coating on the surface of the disc.
Preferably, the coating that the Thickness Ratio that protective coating clamping strap manufactured has manufactures in other parts of dish is larger.Coating in the part different from the part of clamping strap can have the thickness of 20 to 80 μm.
At clamping strap place, the protective coating with same thickness can be manufactured on two contrary braking surfaces.The solution of replacement can be provided, wherein, two braking surfaces of clamping strap manufacture the different coating of thickness.
According to a particularly preferred embodiment of the method, deposition step b) comprise the deposition process of two or more separation of the material of particulate forms on the same surface, to form protective coating.
In more detail, above deposition step b) comprising:
First deposition step of the material of-particulate forms, with the direct base layer producing coating on dish; And
Second deposition step of the material of-particulate forms, to produce finishing coat on the base layer.
Deposition step is divided into the differentiation that two or more process allows especially at least in the granularity of material being used for the particulate forms in different processes.This just makes deposition step more flexible.
Advantageously, the material that the fineness ratio that the material of the particulate forms deposited in the first deposition process has deposits in the second deposition process is larger.Particularly, the material of the particulate forms deposited in the first deposition process has the granularity of 30 to 40 μm, and the material of the particulate forms deposited in the second deposition process has the granularity at 5 to 20 μm.
Coating is realized respectively in two independent deposition process, more coarse granularity is used for base layer and by meticulousr granularity for the formation of finishing coat, make to obtain so a kind of coating and become possibility, this coating has had the surface treatment feature of expectation at the end of deposition, without the need to revising and/or perform other surface treatment operations on the surface of the coating.The particle deposited in the second process will fill the coarse surface of base layer.Advantageously, by adjusting the granularity of the particle deposited in the second process, the surface-treated degree of coating can be adjusted.
Particularly, the particle of the granularity with 30 to 40 μm is used for the first process and the particle of the granularity with 5 to 20 μm is used for the second process, protective coating has the surface roughness Ra of 2.0 to 3.0 μm on finishing coat.
Jointly, there is HVOF, HVAF or KM deposition technique of the material of particulate forms, the chemical component used, and making the so a kind of coating of enough acquisitions become possibility with the combination of the deposition process of multiple step, the surface roughness of the limited grade that this coating has is particularly suitable for the object of brake disc 1 purposes.
Preferably, the thickness that the base layer of coating has is 2/4 to 3/4 of the total thickness of coating, and the thickness that finishing coat has is 1/4 to 2/4 of the total thickness of coating.
Be understandable that from specification, the shortcoming of prior art can be overcome according to brake disc of the present invention.
Brake disc 1 according to the present invention has lightness (owing to employing aluminum or aluminum alloy), wear resistance (owing to employing the mixture of described component) and durability concurrently.
Particularly, dish 1 has protective coating (this coating at least covers clamping strap), and this coating has:
-high-bond, which ensure that and be anchored to dish to heavens;
-high wear resistance;
-limited surface roughness;
-high density;
-high hardness; And
Limited porosity.
The danger not having nickel significantly can reduce coating to be separated with aluminium base or aluminum alloy.
The manufacture of brake disc 1 is also economical.
Object of the present invention also relates to a kind of disk type braker, and it comprises:
-brake disc 1, this brake disc comprises clamping strap 2, and this clamping strap is provided with two contrary braking surface 2a, 2b, and each braking surface limits one in two masters of brake disc at least in part; And
-friction element, is suitable for receiving order and coordinating with braking surface 2a, 2b, to determine braking action by friction.
Brake disc 1 is manufactured according to foregoing.
As described in following continuation, the resistant properties of the coating of the brake disc described above 1 manufactured (and thus, the wear resistance of brake disc 1 specifically), by combinationally using with the friction element of the target of the present invention that will be discussed in more detail below, strengthened collaboratively.
According to the present invention, each friction element form of liner (its specifically) comprises the friction portion consisted of the following composition:
-weight percentage is the abrasives of 10% to 40%;
-weight percentage is the oiling agent of 8% to 40%
-weight percentage is the steel fiber of 5% to 30%;
-weight percentage is the organic bond of 6% to 18%;
-weight percentage is the mineral filler of 10% to 20%;
-percentage trim component is organic fill.
Preferably, the steel fiber that the oiling agent that abrasives, weight percentage that this friction portion is 25% to 30% by weight percentage are 25% to 35%, weight percentage are 15% to 20%, weight percentage be 8% to 15% organic bond and weight percentage be 10% to 20% mineral filler form, trim component is made up of organic fill.
According to a particularly preferred embodiment, abrasives is the particulate forms with the granularity being no more than 60 μm.Have been found that polishing particles that choice for use has an above granularity is for particular importance the balance realized between the frictional behaviour of brake disc 1 and wearing and tearing.
Preferably, abrasives comprises the particle of aluminium oxide and/or periclase.
According to a particularly preferred embodiment, aluminium oxide and periclase are all present in friction portion.Particularly, the granularity of periclase is greater than aluminium oxide, such as, and the granularity that periclase is about 40 μm, the granularity that aluminium oxide is about 30 μm.
According to a particularly preferred embodiment, oiling agent is the particulate forms of the granularity had between 350 μm and 750 μm.
Preferably, this oiling agent comprises graphite and/or coke.
According to a particularly preferred embodiment, graphite and coke are all present in friction portion.Particularly, the granularity of graphite is greater than coke, such as, and the granularity that graphite is about 600 μm, the granularity that coke is about 400 μm.
Preferably, steel fiber comprises copper fiber and/or iron fiber.In the particularly preferred mode of one, friction portion comprises copper fiber and iron fiber.
Preferably, the weight percentage of copper fiber is not more than 5% weight percentage.In these special circumstances, the weight percentage of iron fiber is greater than 5%.
Also can arrange at friction portion, sponge iron (sponge iron), it is combined with iron fiber or as a kind of alternative of iron fiber.
Preferably, organic bond is phenolic resin.
Preferably, mineral filler comprises barite and/or vermiculite.In the particularly preferred mode of one, friction portion comprises barite and vermiculite.Particularly, bar weight percentage is approximately the twice of the weight percentage of vermiculite.Such as, barite weight percentage is be approximately 10%, and vermiculite weight percentage is be approximately 5%.
Preferably, organic fill comprises rubber and/or aramid fibre.In the particularly preferred mode of one, friction portion comprises rubber (preferably having the particulate forms of the granularity of about 1mm) and aramid fibre.Particularly, the weight percentage of rubber is approximately the twice of the weight percentage of aramid fibre.Such as, rubber weight percentage is be approximately 4%, and aramid fibre weight percentage is be approximately 1%.
Preferably, create friction according to following operation the friction portion of element:
A) the uniform as far as possible mixture of following composition is obtained: abrasives; Oiling agent; Steel fiber; Organic bond; Mineral filler; And organic fill;
B) this mixture is pressed into mold heat to obtain preformed friction portion.After three initial degas circulation, pressure must be applied in a continuous manner, to complete the polymerization of organic resin;
C), at the temperature between 200 DEG C and 280 DEG C, in static furnace, Post RDBMS process is carried out to friction portion and any other is designed for the Surface heat-treatent of frictional behavior improving friction material, to carry out surface treatment to friction portion.
Friction element be mat form in particular cases, friction portion can at molded (extruding) step b) place is associated with dunnage (it is made up of metal or plastic materials specifically), or this friction portion can at molded (extruding) step b) after be associated with dunnage by gluing or mechanical connection.
Particularly, under 150 DEG C and predetermined pressure, molding process b is performed).
According to a particularly preferred embodiment, be not less than 250kg/cm
2pressure under implement molding process b), be preferably not less than 550kg/cm
2.
Particularly, molding process b is performed at the temperature between 130 DEG C and 170 DEG C).
Advantageously, implement molding process b) time be no less than 5 minutes, be polymerized to allow organic bond.
Friction portion has 2 and 3g/cm
3between density, the friction portion of each friction element has 2.20 and 2.60g/cm
3between density.
Friction portion have not higher than 10% porosity.
Feature according to friction material of the present invention is, has lower density and lower porosity compared with standard friction material.Usually, in fact, traditional friction material has 2.5 and 3.5Kg/cm
3between density and porosity between 10% and 25%.
This lower density is particularly correlated with the following fact: compared with traditional material, friction material according to the present invention has lower composition weight content, particularly metal and barite under high density.
This low-porosity may be the high molding pressure in the molding process owing to providing in the present invention, higher than usually providing 100 and 200Kg/cm
2between the production standard of value.
Advantageously, the friction portion of each friction element has the rupture modulus being greater than 20MPa.
Advantageously, the friction portion of each friction element has the Young's modulus being greater than 8GPa.
Therefore, friction material according to the present invention has high mechanical features, and it has maximum value or its value had higher than value detectable on market.
The mean value (value between 15 and 20MPa) of a little higher than conventional friction material of this rupture modulus, and Young's modulus is obviously higher.In other words, this shows that friction material according to the present invention is harder material.In fact, for Young's modulus, traditional material has the value of scope between 4GPa and 8GPa.
Usually, in friction material, use steel fiber to strengthen mechanical features.Friction material according to the present invention has better mechanical features (rupture modulus and Young's modulus), although have the steel fiber of less amount on weight percentage.This may owing to the lower porosity of material according to the invention.
Feature according to disk type braker of the present invention is, the combination meter of brake disc 1 and above-mentioned friction element reveals good friction and couples, and has homogeneous performance and very limited wearing and tearing.
It is below the result of performed experimental test.
Test bed testing is carried out to following system:
-have according to protective coating of the present invention and there is the aluminum Moving plate 1 (being called system A hereinafter) of brake pad of the friction portion manufactured by material according to the invention;
-there is aluminum Moving plate 1 (being called system B hereinafter) according to protective coating of the present invention and traditional braking pad;
-there is no coating but there is the aluminum Moving plate 1 (being called system C hereinafter) of brake pad of the friction portion manufactured by material according to the invention.
Particularly, this protective coating is manufactured according to above preferred embodiment.And, manufacture this friction material according to above preferred embodiment.
The standard material had on the vehicle of cast iron brake disk friction material for referencial use will be provided as.The feature of this material is porosity in above-mentioned typical range and mechanical property.
Perform the test of two types: the main AK test on testing results and dynamic stand.
This testing results is carried out by following operation:
100 braking maneuvers; Initial velocity 60km/h and terminate speed 10km/h; Initial temperature=60 DEG C of brake disc; Retardation 0.3g; Sense of rotation is forward direction.The object of this testing results is with brand-new Moving plate-brake pad verification efficiency in friction factor.Then check the wearing and tearing of brake disc and brake pad and tear.Finally, the visual appearance inspection of brake disc is carried out.
Result at the end of table 1 shows testing results.Fig. 3, Fig. 4 and Fig. 5 respectively illustrate the photo relating to the state of clamping strap after the testing results of system A, B and C.It should be noted that at the end of testing results, system C shows the poor state of brake disc and the wearing and tearing completely of brake pad.
Table 1
SAE-J2522 method according to the correction had for limiting maximum temperature carries out main AK test at dynamic stand place.
This main AK test is designed in different condition (temperature and energy load) test this, the performance of system.Then check the wearing and tearing of brake disc and brake pad and tear.Finally, the visual appearance inspection of brake disc is carried out.
Table 2 shows the result at the end of main AK tests.System C weares and teares completely and tests due to the poor and brake pad of the state of brake disc after testing results.Fig. 6 and Fig. 7 respectively illustrates the photo relating to the state of clamping strap after the testing results of system A and B.It should be noted that system B shows crack in the coating at the end of test at the end of main AK test.
Table 2
These tests show, show good friction couple according to brake disc of the present invention (system A) between brake disc and brake pad, have homogeneous performance (mean value of μ is gratifying) and very limited wearing and tearing.Particularly, compared with system B, system A according to the present invention has the tool-wear grade of brake disc higher a little, but has the tool-wear grade of much lower pad.
Particularly, it should be noted that according to coupling between brake disc 1 of the present invention and brake pad (system A) be in wear resistance, be to provide coupling of better performance.
In fact, when system C, that is, when the coupling of pad according to the present invention and non-coated aluminum Moving plate, it should be noted that pad according to the present invention shows poor performance after testing results.In fact, find that this pad grinds off completely.
When system B; namely; when conventional cushion with have protective coating according to the coupling of aluminum Moving plate 1 of the present invention; it should be noted that at the end of main AK test, although brake disc 1 does not wear and tear; but in the coating there is crack; this crack exposes brake disc, makes coating be separated with brake disc at short notice, then performance rapid deterioration.
Only when system A (according to dish 1 of the present invention with according to coupling between pad of the present invention, brake disc wear (reduction) and brake pad wear (not existing) and keep coating complete between have good compromise.
As understood from specification, brake disc according to the present invention allows the shortcoming overcoming prior art.
Feature is, by the combination of brake disc 1 and above-mentioned friction element, disk type braker according to the present invention shows good friction and couples, and has homogeneous performance and very limited wearing and tearing.
Particularly, the performance that can strengthen through frayed all parts (i.e. brake disc and brake pad) is coupled according to of the present invention.
Particularly, when combinationally using with brake pad according to the present invention, brake disc 1 according to the present invention has lightness (if it is made up of aluminum or aluminum alloy), wear resistance and durability concurrently.
Particularly, brake disc 1 is provided with protective coating (it at least covers clamping strap), and this protective coating has:
-high bond strength, this can guarantee anchoring to heavens on the disc brake rotor;
-high wear resistance;
-at high temperature (this protective coating is tested) to the ability worked at up to the temperature of 500 DEG C;
-limited surface roughness rank;
-high density;
-high hardness; And
-limited porosity.
If be made up of aluminum or aluminum alloy, so there is not the danger that nickel significantly can reduce coating segregation.
In addition, the manufacture of brake disc 1 is also economical.
The physical property of traditional material is better than according to the physical property (density and porosity) of friction material of the present invention.
According to the mechanical property (rupture modulus and Young's modulus) of friction material of the present invention also higher than the mechanical property of traditional material, there is the lower steel fiber of weight percent content and barite simultaneously.
Those skilled in the art can carry out multiple amendment and modification to the method and above-mentioned brake disc manufacturing brake disc, to meet possible and concrete requirement, but simultaneously still in the protection scope of the present invention be defined by the following claims.
Claims (19)
1. manufacture a method for brake disc, described method comprises following operating procedure:
A) brake disc is provided, described brake disc comprises clamping strap (2), described clamping strap is made up of aluminum or aluminum alloy and is provided with two contrary braking surfaces (2a, 2b), and each described braking surface limits one in two masters of described brake disc at least in part;
B) with HVOF (high velocity oxygen fuel spraying) technology or HVAF (velocity air fuel spraying) technology or KM (kinetic metallization) technology by the deposition of material of particulate forms on described brake disc; to form the protective coating (3) of at least one braking surface in two braking surfaces covering described clamping strap, Tungsten carbite, weight percentage that the material of described particulate forms is 80% to 90% by weight percentage be 8% to 12% cobalt and weight percentage be 2% to 6% chromium form.
2. method according to claim 1, wherein, Tungsten carbite, weight percentage that the material of described particulate forms is 86% by weight percentage be 10% cobalt and weight percentage be 4% chromium form.
3. method according to claim 1 and 2, wherein, the granularity of the particle of the material of described particulate forms is between 5 to 40 μm.
4. the method according to claim 1,2 or 3, wherein, described protective coating has the thickness of 20 μm to 80 μm.
5. according to described method one or more in aforementioned claim, wherein, deposition step b) comprise material two or more independent deposition process in similar face of described particulate forms, to form described protective coating.
6. method according to claim 5; wherein; deposition step b) comprise the first deposition process of the material of described particulate forms; thus on described brake disc, directly produce the base layer of described protective coating; and the second deposition process of the material of described particulate forms; thus finishing coat is produced on described base layer, the granularity of the material of the described particulate forms deposited in described first deposition process is greater than the granularity of the material of the described particulate forms deposited in described second deposition process.
7. method according to claim 6, wherein, the material of the described particulate forms deposited in described first deposition process has the granularity of 30 to 40 μm, and the material of the described particulate forms deposited in described second deposition process has the granularity of 5 to 20 μm.
8. the method according to claim 6 or 7, wherein, described protective coating has the surface roughness Ra of 2.0 to 3.0 μm at described finishing coat place.
9., according to described method one or more in aforementioned claim, wherein, whole described brake disc is made up of aluminum or aluminum alloy.
10. according to described method one or more in aforementioned claim, wherein, at deposition step b) in, the material of described particulate forms at least based on described protective coating thickness and be deposited in the mode of differentiation on the surface of described brake disc.
11. methods according to claim 11, wherein, each master of described brake disc is at least limited by the first annular portion (2) corresponding with the braking surface of described clamping strap, and limited by the second annular portion (4), described second annular portion than described first annular portion more inwardly and limit the attachment area of described brake disc and vehicle, at deposition step b) in, form the protective coating at least covering these two parts, the thickness that the coating that the Thickness Ratio that the coating that described first annular portion is formed has is formed on described second annular portion has is larger.
12. 1 kinds of brake discs for disk type braker, described brake disc comprises clamping strap (2), described clamping strap is made up of aluminum or aluminum alloy and is had two contrary braking surface (2a, 2b), each described braking surface limits one in two masters of described brake disc (1) at least in part, described brake disc has protective coating (3), described protective coating covers at least one in two described braking surfaces of described clamping strap, described protective coating is the Tungsten carbite of 80% to 90% by weight percentage, weight percentage be 8% to 12% cobalt and weight percentage be 2% to 6% chromium composition, by using HVOF technology, or HVAF (velocity air fuel spraying) technology or KM (kinetic metallization) technology deposit the component of the particulate forms of described protective coating on described brake disc, obtain described protective coating.
13. brake discs according to claim 12, wherein, Tungsten carbite, weight percentage that described protective coating is 86% by weight percentage be 10% cobalt and weight percentage be 4% chromium form.
14. brake discs according to claim 12 or 13, wherein, by the component of deposit grain size on described brake disc the described particulate forms of 5 to 40 μm, obtain described protective coating.
15. brake discs according to claim 12,13 or 14, wherein, described protective coating has the thickness of 20 μm to 80 μm.
16. according to claim 12 to described brake disc one or more in 15; wherein; described protective coating is made up of base layer and finishing coat; described base layer is directly related with described brake disc and made by the first deposition process of the material of particulate forms; described finishing coat to be arranged on described base layer and to be made by the second deposition process of the material of particulate forms, and the granularity that the material of the described particulate forms that the fineness ratio that the material of the described particulate forms deposited in described first deposition process has deposits in described second deposition process has is larger.
17. brake discs according to claim 16, wherein, described protective coating has the surface roughness Ra of 2.0 to 3.0 μm at described finishing coat place.
18. according to claim 12 to described brake disc one or more in 17, and wherein, described protective coating has different thickness in the zones of different on the surface of described brake disc.
19. 1 kinds of disk type brakers, comprising:
-brake disc (1), described brake disc comprises clamping strap (2), described clamping strap is provided with two contrary braking surfaces (2a, 2b), and each described braking surface limits one in two masters of described brake disc at least in part;
-friction element, described friction element is suitable for taking orders and coordinating with described braking surface (2a, 2b), to determine braking action by friction,
It is characterized in that, described brake disc (1) is provided with protective coating (3), described protective coating covers at least one in two braking surfaces of described clamping strap, described protective coating is the Tungsten carbite of 80% to 90% by weight percentage, weight percentage be 8% to 12% cobalt and weight percentage be 2% to 6% chromium composition, by HVOF (high velocity oxygen fuel spraying) technology of plasma spraying, or HVAF (velocity air fuel spraying) technology or KM (kinetic metallization) technology deposit the component of the particulate forms of described protective coating on described brake disc, obtain described protective coating, and, it is the abrasives of 10% to 40% that each friction element comprises by weight percentage, weight percentage is the oiling agent of 8% to 40%, weight percentage is the steel fiber of 5% to 30%, weight percentage be 6% to 18% organic bond and weight percentage be 10% to 20% mineral filler composition friction portion, trim component is made up of organic fill, described friction portion has 2 to 3g/cm
3density and be not more than 10% porosity.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ITPD2012A000403 | 2012-12-21 | ||
| IT000404A ITPD20120404A1 (en) | 2012-12-21 | 2012-12-21 | DISC BRAKE |
| IT000403A ITPD20120403A1 (en) | 2012-12-21 | 2012-12-21 | METHOD TO BUILD A BRAKE DISC AND BRAKE DISC FOR DISC BRAKES |
| ITPD2012A000404 | 2012-12-21 | ||
| PCT/IB2013/061104 WO2014097186A1 (en) | 2012-12-21 | 2013-12-18 | A method of making a brake disc, brake disc for disc brake and a disc brake |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN104995425A true CN104995425A (en) | 2015-10-21 |
| CN104995425B CN104995425B (en) | 2021-05-07 |
Family
ID=50064736
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201380072767.9A Active CN104995425B (en) | 2012-12-21 | 2013-12-18 | Method for manufacturing a brake disc, disc brake and brake disc therefor |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US9879740B2 (en) |
| EP (1) | EP2935930B1 (en) |
| JP (1) | JP6347790B2 (en) |
| CN (1) | CN104995425B (en) |
| MX (1) | MX2015008179A (en) |
| WO (1) | WO2014097186A1 (en) |
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| CN110754953B (en) * | 2018-07-27 | 2022-03-22 | 佛山市顺德区美的电热电器制造有限公司 | Quasi-crystal coating, preparation method thereof, cookware and application of cookware |
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| CN111139419A (en) * | 2018-11-02 | 2020-05-12 | 佛山市顺德区美的电热电器制造有限公司 | Container, preparation method thereof and cooking equipment |
| CN113195924A (en) * | 2018-12-21 | 2021-07-30 | 乐姆宝公开有限公司 | Method for producing a brake disc and brake disc for a disc brake |
| CN113195924B (en) * | 2018-12-21 | 2023-09-19 | 乐姆宝公开有限公司 | Method for producing a brake disk and brake disk for a disk brake |
| CN114929530A (en) * | 2019-12-20 | 2022-08-19 | 乐姆宝公开有限公司 | Braking band for a disc of a disc brake |
Also Published As
| Publication number | Publication date |
|---|---|
| CN104995425B (en) | 2021-05-07 |
| US9879740B2 (en) | 2018-01-30 |
| JP2016503148A (en) | 2016-02-01 |
| US20150354647A1 (en) | 2015-12-10 |
| EP2935930A1 (en) | 2015-10-28 |
| EP2935930B1 (en) | 2019-09-18 |
| JP6347790B2 (en) | 2018-06-27 |
| WO2014097186A1 (en) | 2014-06-26 |
| MX2015008179A (en) | 2016-02-05 |
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